Maxsys Fuel System helps packaging manufacturer pulp gas bills

The installation of the increasingly popular Fuel System from Maxsys at the Launceston site of DS Smith Speciality Packaging has led to a 5.8% annual reduction in gas consumption – resulting in an impressive financial saving of thousands of pounds per year.

Established for 40 years, the Launceston facility of DS Smith Speciality Packaging, part of the £1.7 billion DS Smith International Group, is a hybrid plant manufacturing both conventional packaging and speciality packs, and claims to be the UK’s foremost corrugated packaging manufacture. Products include high volume cardboard transit cases as well as speciality, decorative and heavy duty packaging.

For over a century corrugated cardboard has been a faithful packaging servant. The humble brown box both protects and attracts despite competition from returnable plastics containers, stretch wrapped pallets and intermediate bulk solutions. To survive in a competitive world it is innovation that will count in the future. This factor has long been realised by DS Smith Speciality Packaging, both in terms of its products and processes.

“With the cost of energy escalating massively and the increasing need to reduce carbon footprint, it seemed sensible to stage a review of our boiler plant,” explains the company’s quality manager Steve Porter. “I’d retained a mail drop from Maxsys about the Fuel System a few months earlier and so decided to give them a call.”

The ISO 9001:2000 and ISO14001-accredited company runs two ageing Danks gas-fired, steam-raising boilers at Launceston, which are used for both general heating and process heat.

“Looking at the mail drop I was impressed by the many testimonials listed by satisfied customers,” says Mr Porter.

In the months leading up to winter 2006, Maxsys fitted a the Fuel System to each of the Danks boilers at DS Smith Launceston site. The Fuel System is a well established fuel treatment technology that improves combustion by applying a finely calibrated magnetic field directly to the fuel.

“The results have been fantastic,” states Mr Porter. “Not only have we reduced our carbon emissions by cutting gas consumption by 5.8%, we have also made substantial financial savings in the 12 months since installation.”

A test protocol, for the assessment of the boiler plant performance with and without the Maxsys Fuel System technology in place, was produced and agreed by both parties. Meter readings were then gathered three times a day by DS Smith Speciality Packaging for the duration of the test protocol period. The evaluation was based on the established CUSUM statistical model with regenerative analysis. The results identified that average gas consumption was 5.8% lower following installation of the FuelSystems.

The new technology also helped the Cornwall plant carry off the top prize in the paper and packaging category of the National Green Apple Awards 2007, which recognise environmental achievement. The facility won the prize for reducing emissions to air, water and ground as well as working closely with local residents on environmental issues.

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